US3379609A - Water-felted building product including nonfibrous cellulose binder - Google Patents

Water-felted building product including nonfibrous cellulose binder Download PDF

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Publication number
US3379609A
US3379609A US338057A US33805764A US3379609A US 3379609 A US3379609 A US 3379609A US 338057 A US338057 A US 338057A US 33805764 A US33805764 A US 33805764A US 3379609 A US3379609 A US 3379609A
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United States
Prior art keywords
perlite
product
products
percent
water
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Expired - Lifetime
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US338057A
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English (en)
Inventor
James R Roberts
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United States Gypsum Co
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United States Gypsum Co
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Publication date
Application filed by United States Gypsum Co filed Critical United States Gypsum Co
Priority to US338057A priority Critical patent/US3379609A/en
Priority to GB53055/64A priority patent/GB1101954A/en
Priority to DEU11374A priority patent/DE1246515B/de
Priority to BE658352D priority patent/BE658352A/xx
Priority to SE566/65A priority patent/SE342437B/xx
Priority to FR2156A priority patent/FR1420990A/fr
Priority to NO156387A priority patent/NO120357B/no
Priority to NL6500529A priority patent/NL6500529A/xx
Priority to LU47789A priority patent/LU47789A1/xx
Application granted granted Critical
Publication of US3379609A publication Critical patent/US3379609A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H5/00Special paper or cardboard not otherwise provided for
    • D21H5/12Special paper or cardboard not otherwise provided for characterised by the use of special fibrous materials
    • D21H5/18Special paper or cardboard not otherwise provided for characterised by the use of special fibrous materials of inorganic fibres with or without cellulose fibres
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02Macromolecular compounds
    • C04B26/28Polysaccharides or derivatives thereof
    • C04B26/285Cellulose or derivatives thereof
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/001Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing unburned clay
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H11/00Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only
    • D21H11/02Chemical or chemomechanical or chemothermomechanical pulp
    • D21H11/04Kraft or sulfate pulp
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/36Inorganic fibres or flakes
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/36Inorganic fibres or flakes
    • D21H13/38Inorganic fibres or flakes siliceous
    • D21H13/40Inorganic fibres or flakes siliceous vitreous, e.g. mineral wool, glass fibres
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21JFIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J1/00Fibreboard

Definitions

  • This invention relates to the production of unied monolithic building products and more particularly to improved unified, lightweight building products in sheet form containing perlite and a cellulosic binder.
  • lExpanded perlite is a well known commercial lightweight mineral aggregate, produced by the thermal expansion of the volcanic glass perlite.
  • the product is cellular or vesicular in form, ordinarily having an essentially sperical shape.
  • the product produced by commercial operations contains a bro'ad range of particles sizes.
  • a further object is the provision of a building product which has superior compression and abrasion resistance.
  • a still further object is the provision of a building product which has excellent structural integrity Iachieved without the use of synthetic organic fibers, asphalt or other synthetic binders.
  • Another object is the provision of a monolithic building product which has excellent fire resistance.
  • Another object is the provision of a monolithic building product in sheet form which has improved sound absorption and attenuation properties.
  • Another object is the provision of a unified building product in sheet form which has surfaces which are 'adapted for finishing.
  • Another object is the provision of a building product in sheet form Which has superior thermal insulating properties.
  • the present invention 3,37%,609 Patented Apr. 23, 1968 rice comprises ya unified lightweight monolithic building product in sheet form, said unified product comprising one part of a mechanically induced w'ater activated cellulosic binder and from about 5/3 to 9 parts by weight (dry basis) of a thermally expanded perlite.
  • the proportions of perlite range from 7/3 to 8.5 parts.
  • the present invention comprises building products which contain 'a minor proportion of a ceramic clay, specifically up to about 2 parts clay per part of cellulostic binder, and in the most preferred instances from 1/3 to 2 parts of clay per part of cellulosic binder.
  • compositions may also optionally contain boric 'acid as a re retardant and small amounts of a wax for water repellancy.
  • Waxes such as microcrystalline wax, petroleum Wax, paraflin waxes and the like, are suitable.
  • the wax when used, is usu'ally in amounts up to about 2 percent by weight and preferably from 0.25 to 1 percent by weight.
  • the boric acid is ygenerally incorporated into the product in amounts up to 3 percent by weight, and preferably from 0.25 percent to 2 percent.
  • Alum may also be incorporated for superior processing in amounts of from about 1/2 to 11/2 percent.
  • the minor additives, i.e. boric acid, wax and alum are expressed as percentages of the total product weight. All parts and percentages referred to herein, unless otherwise stated, should be understood to be on a dry weight basis.
  • the products of the present invention are lightweight, i.e. having densities in the broadest aspects of from about 4 to about 25 pounds per cubic foot, prefer'ably from 8 to 20 pounds per cubic foot.
  • compositions o-f the present invention which contain clay in addition to perlite and cellulosic binder are especially useful in fire resisting applications.
  • the clay used is of the high alumina and silica, ceramic variety and is characterized as nonswellinig.
  • Clays such as kaolin, fire clay, brick clay and ball clay, are exemplary.
  • the iirst resistant building product contains from about 50 to 80 percent perlite, from l() to 3'0' percent cellulosic binder and from 10 to 20 percent ceramic clay.
  • the clay is especially valuable in the production of fire rated tile.
  • the clay containing tiles or wallbo'ard products sinter, rather than spall or undergo 3 gross delamination or support combustion, as in the case of other materials.
  • the products of the present invention may, as previousiy pointed out, also be used in the production of building materialsl for sound ⁇ and thermal insulation wherein the surface is exposed to view.
  • ceiling tile or board products of the present invention which may be painted, or if desired surfaced on one or both sides with paper sheets to form a laminated or sandwich construction.
  • the products may also be used to prepare acoustical, drilled or perforated tile by conventional techniques.
  • the perlite which is used in the products of the present invention may be of a variety of mesh sizes. Generally mesh sizes of less than 8 mesh are suitable for structural insulating boards and underlayrnent. For those applications which require a smooth finish on the surface of the product, i.e. ceiling tile, it is preferred to use a finer perlite, preferably one in which at least 70 percent passes a mesh screen, and which has no particles larger than 8 mesh (US. Standard Sieve Series).
  • the cellulosic binder is a highly hydrated gelatinous substance.
  • the starting material may be any cellulosic material, preferably an unbleached waste lkraft stock. lt has been found that extended refining of the pulp results in a change of properties and the cellulose is converted thereby from a fibrous material to an essentially nonfibrous gelatinous substance. With this refining treatment it has been found that the properties of the cellulose change to such an extent that the material acts essentially 'as an adhesive without liber interfeltinlg action. The degree of hydration may be expressed in terms of Schopper-Riegler freeness.
  • the products of the present invention are mechanically hydrated to a Schopper-Riegler freeness of less than about 100 m1. and preferably less t-han about 90 ml.
  • the increasing hydration results in superior strength of the products when the cellulose material is used in the products of the present invention.
  • the effect of the refining or Schopper-Riegler freeness is shown in the subjoined table.
  • the series refining steps referred to in the above table are passes of the pulp through a Morden Stockmaker type pulp renner equipped with lava tackle.
  • a paper source preferably yan unbleached waste kraft paper source, which discharges into a hydropulper of the Morden Slushmaker type, and water is added to form a kraft paper fiber furnish having a consistency of at least about 6 percent.
  • the discharge from the hydropulper is passed to a stock tank and then through a series of pulp refiners (A, B, C, D), such as preferably of the Morden type equipped with lav'a tackle.
  • the pulp from refiner A is discharged into a refiner B and thence to refiners C and D in cascade sequence with a total residence time of about 15 seconds.
  • the final product has a Schoppler-Riegler freeness of less than about 100.
  • the cellulosic binder discharge from the reiiner sequence is highly hydrated and essentially nonfibrous in character.
  • the cellulosic binder is passed to a stock tank for storage and supply. At intervals the cellulosic binder is passed to a mixing chest where perlite in the desired amount is added. Clay from source may also be added to the mix if desired in the particular embodiment.
  • Water may be added from the source to adjust the con-sisten-cy of the mix to from about 4 to about 8 percent although the consistency may also be adjusted in the furnish making stage.
  • Other additives such as bon'c acid, Wax, and alum, as desired, may be added at this point.
  • the contents of the mixing chest are discharged to the machine chest and thence onto the screen of the Fourdrinier machine.
  • Other types of paper, board or sheet making machines such as cylinder machines and the like may be employed, if desired.
  • the slurry of cellulosic binder, perlite, and/or other additives is deposited or laid on the screen or wire in an initial thickness of from about 3A to 4 inches.
  • the web thus formed is compacted in the press section by roller presses or the like to a thickness of from about 1/2 to 11/2 inches, and thence to 'a drier, preferably of the multiple deck variety.
  • the dried product in sheet form is trimmed and cut to the desired size and passed to a storage or for further finishing, such as by painting, lamination of paper sheets on one or both surfaces, larninations of the sheet, perforations, or the like.
  • Insulation products were made by the process of the present invention containing varying amounts of perlite, cellulosic binder, clay and other additives. Each product was laminated with paper sheets on both surfaces to illustrate the results obtained with the laminated as compared with the unlaminated product.
  • the following examples illustrate the composition and physical properties of the sheet products made in accordance with this invention.
  • Example 7 Laminated on both surfaces with manila faced shipboard sheet having a weight of 72 pounds per 1,000 square feet.
  • Polyvinyl acetate adhesive (Du Pont Elvacet) inch Example 7 This example illustrates the commercial production of a lightweight insulation product of the present invention which has utility as a sound deadening board. The preparation follows the procedure described above. The following table shaws the proportions of each component in the final product in terms of percentage composition and weight.
  • the water activated cellulose binder from the last refiner had a Schopper-Riegler freeness of less than 100.
  • the cellulosic binder dispersion at a consistency of about 6 percent was passed to a stock tank and then to a mixing chest for admixture with water (166,400 pounds), clay, perlite, boric acid, wax and alum in the amounts indicated.
  • the perlite had a mesh size range of about -20 to +200 (70%).
  • the clay was a ceramic type ball clay (Kentucky-Tennessee Clay Co., CTS-1) having the following analysis:
  • the wax was a microcrystalline wax-Mobil Oil Co. Mobilcere-RV emulsion.
  • the product from the mixing tank with a consistency of about 4 percent was passed to the Fourdrinier machine and formed into a sheet which, after pressing and drying, had a thickness of about 3%; inch.
  • the products of the present invention are characterized by excellent fire resistance.
  • the products containing perlite, binder and clay have a class 1 rating by ASTM E84-61 (Underwriters Laboratories Standard 723).
  • the products also have a Class A rating according to Federal Specification SS-A-00l18c (Apr. 14, 1960).
  • cellulosic binder material and the water felted insulating and building products of the present invention are readily prepared in a variety of forms by the processes outlined above.
  • the method described may also be modified with respect to .the equipment used in manufacture, such substitution being conventional in this art.
  • a method of producing a unified monolithic building product in sheet form which comprises forming a gelatinous cellulosic binder by dispersing a kraft fiber in water to form a slurry of up to about 6% consistency, continuously passing the slurry through a series of pulp refiners having abrading surfaces preset to gelatininizing conditions for a time and an intensity to produce an essentially nonfibrous gelatinous slurry having a Schopper- Riegler freeness of up to about m1., and a patricle size on the order of up to about 0.06 mm., admixiug the resulting slurry with from 5/ 3 to 9 parts of a thermally eX- panded perlite per part of binder (dry basis) to form an aqueous slurry of a consistency of from 4 to 8 percent, the major proportion of said perlite having a particle size of greater than 200 mesh, forming a felted sheet from said admixture, compressing the felted sheet to expel eX-
  • a lightweight unlied monolithic building product in sheet form comprising a mechanically induced water activated cellulosic gelatinous binder having a Schopper-Riegler freeuess in its original hydrated state of less than about 100 ml.
  • thermoly expanded perlite is present in proportions of from about 7/ 3 to 8.5 parts per part of cellulosic binder (dry basis).

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  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Structural Engineering (AREA)
  • General Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Building Environments (AREA)
  • Paper (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Laminated Bodies (AREA)
US338057A 1964-01-16 1964-01-16 Water-felted building product including nonfibrous cellulose binder Expired - Lifetime US3379609A (en)

Priority Applications (9)

Application Number Priority Date Filing Date Title
US338057A US3379609A (en) 1964-01-16 1964-01-16 Water-felted building product including nonfibrous cellulose binder
GB53055/64A GB1101954A (en) 1964-01-16 1964-12-31 Building product
BE658352D BE658352A (de) 1964-01-16 1965-01-15
SE566/65A SE342437B (de) 1964-01-16 1965-01-15
DEU11374A DE1246515B (de) 1964-01-16 1965-01-15 Verfahren zur Herstellung von Bau- und Isolierplatten
FR2156A FR1420990A (fr) 1964-01-16 1965-01-15 Produits destinés à la construction et leurs procédés de fabrication
NO156387A NO120357B (de) 1964-01-16 1965-01-15
NL6500529A NL6500529A (de) 1964-01-16 1965-01-15
LU47789A LU47789A1 (de) 1964-01-16 1965-01-15

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US338057A US3379609A (en) 1964-01-16 1964-01-16 Water-felted building product including nonfibrous cellulose binder

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US3379609A true US3379609A (en) 1968-04-23

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US338057A Expired - Lifetime US3379609A (en) 1964-01-16 1964-01-16 Water-felted building product including nonfibrous cellulose binder

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US (1) US3379609A (de)
BE (1) BE658352A (de)
DE (1) DE1246515B (de)
GB (1) GB1101954A (de)
LU (1) LU47789A1 (de)
NL (1) NL6500529A (de)
NO (1) NO120357B (de)
SE (1) SE342437B (de)

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3494824A (en) * 1965-12-27 1970-02-10 United States Gypsum Co Foamed water felted insulation and building product
US3952830A (en) * 1974-05-07 1976-04-27 Grefco, Inc. Mineral aggregate (perlite) acoustical board
US4043862A (en) * 1975-07-21 1977-08-23 Eucatex S. A. Industria E Gomercio Fire resistant vermiculite composition board and method of manufacture
US4087317A (en) * 1975-08-04 1978-05-02 Eucatex S.A. Industria E Comercio High yield, low cost cellulosic pulp and hydrated gels therefrom
US4309247A (en) * 1976-03-15 1982-01-05 Amf Incorporated Filter and method of making same
US4378271A (en) * 1979-10-19 1983-03-29 Turner & Newall Plc Starch bound paper
US4403891A (en) * 1980-10-09 1983-09-13 Toa Grout Kogyo Co., Ltd. Stabilizer for excavated surface
US5871857A (en) * 1988-12-06 1999-02-16 Alhamad; Shaikh Ghaleb Mohammad Yassin Fire resistant construction board
US5911818A (en) * 1997-08-20 1999-06-15 Usg Interiors, Inc. Acoustical tile composition
US20120164422A1 (en) * 2010-12-22 2012-06-28 Usg Interiors, Inc. Ceiling tile base mat
WO2024044105A1 (en) 2022-08-25 2024-02-29 United States Gypsum Company Light-weight fast-dry self-leveling cementitious gypsum underlayment with particle fillers

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2233357B (en) * 1989-06-21 1993-01-06 Timsales Limited Fibreboard and method for production thereof
US5395438A (en) * 1994-01-14 1995-03-07 Usg Interiors, Inc. Mineral wool-free acoustical tile composition

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2426923A (en) * 1942-12-31 1947-09-02 Cowles Co Method for hydrating paper stock
US2634207A (en) * 1947-12-31 1953-04-07 Great Lakes Carbon Corp Building board
US2971878A (en) * 1953-08-21 1961-02-14 Carey Philip Mfg Co Insulation material and method of making same
US3001907A (en) * 1958-11-17 1961-09-26 Wood Conversion Co Manufacture of fire-retardant board
US3066065A (en) * 1959-01-30 1962-11-27 Owens Corning Fiberglass Corp Glass flake electrical insulation

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE927260C (de) * 1950-03-16 1955-05-02 Koppers Gmbh Heinrich Feuerfester Isolierstein
US3095347A (en) * 1958-09-11 1963-06-25 Johns Manville Perlite Corp Insulating material and the like
US3015626A (en) * 1959-09-29 1962-01-02 John C Kingsbury Insulating composition

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2426923A (en) * 1942-12-31 1947-09-02 Cowles Co Method for hydrating paper stock
US2634207A (en) * 1947-12-31 1953-04-07 Great Lakes Carbon Corp Building board
US2971878A (en) * 1953-08-21 1961-02-14 Carey Philip Mfg Co Insulation material and method of making same
US3001907A (en) * 1958-11-17 1961-09-26 Wood Conversion Co Manufacture of fire-retardant board
US3066065A (en) * 1959-01-30 1962-11-27 Owens Corning Fiberglass Corp Glass flake electrical insulation

Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3494824A (en) * 1965-12-27 1970-02-10 United States Gypsum Co Foamed water felted insulation and building product
US3952830A (en) * 1974-05-07 1976-04-27 Grefco, Inc. Mineral aggregate (perlite) acoustical board
US4043862A (en) * 1975-07-21 1977-08-23 Eucatex S. A. Industria E Gomercio Fire resistant vermiculite composition board and method of manufacture
US4077833A (en) * 1975-07-21 1978-03-07 Eucatex S.A. Industria E Comercio Fire resistant, bauxite-containing, wood composition board
US4087317A (en) * 1975-08-04 1978-05-02 Eucatex S.A. Industria E Comercio High yield, low cost cellulosic pulp and hydrated gels therefrom
US4309247A (en) * 1976-03-15 1982-01-05 Amf Incorporated Filter and method of making same
US4378271A (en) * 1979-10-19 1983-03-29 Turner & Newall Plc Starch bound paper
US4403891A (en) * 1980-10-09 1983-09-13 Toa Grout Kogyo Co., Ltd. Stabilizer for excavated surface
US5871857A (en) * 1988-12-06 1999-02-16 Alhamad; Shaikh Ghaleb Mohammad Yassin Fire resistant construction board
US6054088A (en) * 1988-12-06 2000-04-25 Alhamad; Shaikh Ghaleb Mohammad Yassin Method of making a highly fire resistant construction board
US5911818A (en) * 1997-08-20 1999-06-15 Usg Interiors, Inc. Acoustical tile composition
US20120164422A1 (en) * 2010-12-22 2012-06-28 Usg Interiors, Inc. Ceiling tile base mat
US8383233B2 (en) * 2010-12-22 2013-02-26 Usg Interiors, Llc Ceiling tile base mat
JP2014506965A (ja) * 2010-12-22 2014-03-20 ユーエスジー・インテリアズ・エルエルシー 天井タイルのベースマット
AU2011349858B2 (en) * 2010-12-22 2015-07-30 Usg Interiors, Llc Ceiling tile base mat
WO2024044105A1 (en) 2022-08-25 2024-02-29 United States Gypsum Company Light-weight fast-dry self-leveling cementitious gypsum underlayment with particle fillers

Also Published As

Publication number Publication date
LU47789A1 (de) 1965-03-15
GB1101954A (en) 1968-02-07
NO120357B (de) 1970-10-05
NL6500529A (de) 1965-07-19
DE1246515B (de) 1967-08-03
SE342437B (de) 1972-02-07
BE658352A (de) 1965-04-30

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